Plunger Cup for High Efficiency Toilets

ABSTRACT

A plunger cup has a unitary body with curved outer and inner surfaces that extend to a circumferential edge. A sealing flange extends outwardly from the unitary body about the circumferential edge, and supporting structure is formed in the unitary body.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 61/718,234, filed Oct. 25, 2012.

TECHNICAL FIELD

This invention generally relates to plungers for dislodging clogs from plumbing fixtures and piping, and, in particular, to a plunger cup configuration that is especially effective for dislodging clogs in high efficiency toilets.

BACKGROUND OF THE INVENTION

Toilet bowls define a water and waste collection area that narrows down to an opening that leads to a trapway in the plumbing system. High efficiency toilets have larger openings to the trapway than traditional toilets. These larger trapway openings do not allow traditional plungers to create an efficient seal with the trap way to work effectively.

SUMMARY OF THE INVENTION

In one exemplary embodiment, a plunger cup comprises a unitary body that has curved outer and inner surfaces that extend to a circumferential edge, a sealing flange that extends outwardly from the unitary body about the circumferential edge, and supporting structure formed in the unitary body.

In a further embodiment of the above, the supporting structure comprises a plurality of external ribs.

In a further embodiment of any of the above, the supporting structure comprises a plurality of internal ribs.

In a further embodiment of any of the above, the plunger cup includes a seal member extending downwardly and inwardly from the sealing flange.

In a further embodiment of any of the above, the seal member tapers radially inwardly.

In a further embodiment of any of the above, the seal member comprises a first portion defined by a first diameter at the sealing flange and a second portion that forms a distal rim defined by a second diameter that is less than the first diameter.

In a further embodiment of any of the above, the seal member further comprises a third portion that curves radially inwardly to connect the first portion to the second portion.

In a further embodiment of any of the above, the distal rim includes a trapway engagement surface.

In a further embodiment of any of the above, the plunger cup includes a neck extending upwardly from the unitary body.

In a further embodiment of any of the above, the neck comprises a cylindrical portion having a center opening configured to receive a handle.

In a further embodiment of any of the above, the supporting structure comprises at least a plurality of external ribs formed on the outer surface and circumferentially spaced about the neck.

In a further embodiment of any of the above, each rib extends from the neck toward the circumferential edge.

In a further embodiment of any of the above, each rib terminates at a distal end that is spaced from the circumferential edge.

In a further embodiment of any of the above, each rib is thicker at the neck than at the distal end.

In a further embodiment of any of the above, the supporting structure further comprises a plurality of internal ribs formed on the inner surface.

In a further embodiment of any of the above, each internal rib is radially offset from each external rib.

In a further embodiment of any of the above, each internal rib comprises a planar inner facing edge and a curved outer facing edge that is curved to match the inner surface of the unitary body.

These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a plunger cup incorporating the invention.

FIG. 2 is a side view of the plunger cup of FIG. 1.

FIG. 3 is a top view of the plunger cup of FIG. 1.

FIG. 4 is a cross-sectional view taken along section A-A as identified in FIG. 3.

FIG. 5 is a cross-sectional view taken along section B-B as identified in FIG. 3.

FIG. 6 is a cross-sectional view taken along section C-C as identified in FIG. 3.

FIG. 7 is a bottom view of the plunger cup of FIG. 1.

FIG. 8 is a schematic representation of a toilet and trapway.

DETAILED DESCRIPTION

FIG. 1 shows a plunger cup 10 that is used to effectively seal within, and plunge, a toilet trapway 100 for a toilet 102 (FIG. 8). In one example, the plunger cup 10 comprises a unitary body (one-piece construction) that is molded or formed from a resilient material.

The unitary body of the plunger cup 10 includes a curved outer surface 12 and a curved inner surface 14 (FIG. 4). In one example, the unitary body comprises a semi-spherical shaped body that has a determined internal volume. The curved outer 12 and inner 14 surfaces extend to a circumferential edge 16. Formed on the circumferential edge 16 is an outer flange 18 that comprises a sealing flange or member that is designed to improve the seal within the trapway 100.

The plunger cup 10 also includes a neck 20 that extends upwardly from the curved outer surface 12 at an apex of the unitary body. The neck 20 comprises a cylindrical body with a center opening 22 that typically includes threads 24 (FIG. 4) to attach to a handle 26 (FIG. 5) as known. Other attachment methods could also be used to attach the plunger cup 10 to the handle 26.

A seal member 30 extends downwardly and inwardly from the flange 18 and is configured to seal with the toilet trapway 100. The seal member 30 has a continuous profile extending from the flange 18 and extends centrally inward. In one example, the seal member 30 is radially tapered so that a distal rim 32 of the seal member 30 extends into the trapway 100.

The seal member 30 includes a first portion 34 defined by a first diameter D1 at the flange 18 and a second portion 36 that forms the distal rim 32, which is defined by a second diameter D2 that is less than the first diameter D1. The circumferential edge 16 defines a third diameter D3 that comprises the overall diameter of the cup portion. The flange 18 is defined by a fourth diameter D4 that is greater than D3. The fourth diameter D4 comprises the outermost diameter of the plunger cup 10. The neck 20 is defined by a fifth diameter D5 that is less than the third diameter D3. The fifth diameter D5 comprises the smallest diameter portion of the plunger cup 10.

The seal member 30 further includes a third portion 38 that curves radially inwardly to connect the first portion 34 to the second portion 36. The distal rim 32 of the second portion 36 comprises a trapway engagement surface that is inserted within, and seals against, the trapway 100.

In order to properly operate within the increased size and volume of the cup 10, supporting structure 40 is molded or formed directly onto the unitary body. In one example, the supporting structure 40 includes a plurality of external ribs 42. The external ribs 42 are formed to extend outwardly from the curved outer surface 12 of the unitary body. In one example, the external ribs 42 are circumferentially spaced about the neck 20 and extend from the neck 20 in a generally axial direction toward the circumferential edge 16. In one example, each external rib 42 terminates at a distal end 44 that is spaced from the circumferential edge 16. Also, in one exemplary embodiment, each external rib 42 has an upper portion 46 that is thicker and wider at the neck 20 than at a lower portion 48 at the distal end 44. In other words, in one preferred embodiment, each of the external ribs 42 tapers down in width and thickness in a direction extending away from the neck 20 and does not extend all of the way to the flange 18.

The supporting structure 40 also can include a plurality of internal ribs 50 (FIG. 4) formed on the curved inner surface 14 of the unitary body. In one example, each internal rib 50 comprises a planar inner facing edge 52 and a curved outer facing edge 54 that is curved to match the inner surface 14 of the unitary body.

In one example embodiment, the internal ribs 50 are misaligned or offset from the external ribs 42. One manner of accomplishing this offset is to form a different number of internal ribs 50 than external ribs 42. In the example shown, the plunger cup 10 includes six equally spaced external ribs 42 and five equally spaced internal ribs 50. Equal number of the ribs could also be utilized with the ribs simply being positioned such that they are offset and not in radial alignment with each other.

As shown in FIG. 6, the flange 18 is defined by a first height H1 and the cup portion defined by the curved outer 12 and inner 14 surfaces is defined by a second height H2 that is significantly greater than the first height H1. The seal member 30 is defined by a third height H3 that is greater than the first height H1 but less than the second height H2.

The cup portion defined by the curved outer 12 and inner 14 surfaces is defined by a first thickness T1 near the neck 20 and a second thickness T2 at the flange 18. The second thickness T2 is less than the first thickness T1. As such, the thickness of the cup portion gradually lessens in a direction toward the seal member 30. The seal member 30 is defined by a third thickness T3 that is less than the first T1 and second T2 thicknesses.

The subject invention provides a large diameter plunger cup 10 to seal a trapway opening. The increased volume of the cup provides effective plunging of high efficiency toilets. The plunger cup 10 is preferably constructed of a rubber material and includes the supporting structure to prevent flipping while achieving effective rebounding to defeat the created suction.

The combination of the circumferential rim, the size of the cup, and the supporting structure allows for effective rebounding. In the example shown, the supporting structure includes the external and internal ribs that facilitate the rebounding. Preferably, the external and internal ribs are misaligned for more effective rebounding. The effectiveness of the plunger is also dependent upon an optimized ratio of flange height, flange diameter, cup diameter, cup height, rim size, and wall thickness.

Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. 

What is claimed is:
 1. A plunger cup comprising: a unitary body having a curved outer surface and a curved inner surface that extend to a circumferential edge; a sealing flange extending outwardly from the unitary body about the circumferential edge; and supporting structure formed in the unitary body.
 2. The plunger cup according to claim 1, wherein the unitary body comprises a semi-spherical body.
 3. The plunger cup according to claim 1, wherein the supporting structure comprises a plurality of external ribs.
 4. The plunger cup according to claim 1, wherein the supporting structure comprises a plurality of internal ribs.
 5. The plunger cup according to claim 1, including a seal member extending downwardly and inwardly from the sealing flange.
 6. The plunger cup according to claim 5, wherein the seal member tapers radially inwardly.
 7. The plunger cup according to claim 1, wherein the seal member comprises a first portion defined by a first diameter at the sealing flange and a second portion that forms a distal rim defined by a second diameter that is less than the first diameter.
 8. The plunger cup according to claim 7, wherein the seal member further comprises a third portion that curves radially inwardly to connect the first portion to the second portion.
 9. The plunger cup according to claim 7, wherein the distal rim includes a trapway engagement surface.
 10. The plunger cup according to claim 1, including a neck extending upwardly from the unitary body.
 11. The plunger cup according to claim 10, wherein the neck comprises a cylindrical portion having a center opening configured to receive a handle.
 12. The plunger cup according to claim 10, wherein the supporting structure comprises at least a plurality of external ribs formed on the outer surface and circumferentially spaced about the neck.
 13. The plunger cup according to claim 12, wherein each rib extends from the neck toward the circumferential edge.
 14. The plunger cup according to claim 13, wherein each rib terminates at a distal end that is spaced from the circumferential edge.
 15. The plunger cup according to claim 14, wherein each rib is thicker at the neck than at the distal end.
 16. The plunger cup according to claim 12, wherein the supporting structure further comprises a plurality of internal ribs formed on the inner surface.
 17. The plunger cup according to claim 16, wherein each internal rib is radially offset from each external rib.
 18. The plunger cup according to claim 16, wherein each internal rib comprises a planar inner facing edge and a curved outer facing edge that is curved to match the inner surface of the unitary body. 